règlement engins mobiles non routiers eu : non road … · 2018. 10. 10. · 1995 -injection...

Règlement Engins Mobiles Non Routiers EU : NON ROAD ENGINES – IWW STAGE V

Présentation Eneria 20161www.eneria.com

EMISSIONS & POST TRAITEMENT RAPPELS


First CATERPILLAR diesel engine (D9900)

(Model Sixty tractor in 1931)

CATERPILLAR diesel engine C18 STAGE IV

(Power Unit module in 2017)

‐ Nox ‐‐ PM ‐

GLOBAL CATERPILLAR & DIESEL HISTORY / ENGINE EMISSION PERFORMANCE

> 15 g/kWh < 0,5 g/kWh / 30> 1 g/kWh < 0,015 g/kWh / 66

WHAT ARE DIESEL EMISSIONS ?Most of the pollutants originate from various non-ideal processes during combustion, such as :

• incomplete combustion of fuel, • reactions between mixture components under high

temperature and pressure, • combustion of engine lubricating oil and oil additives• combustion of non-hydrocarbon components of diesel fuel,

such as sulfur compounds and fuel additives.

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COMMON POLLUTANTS INCLUDE UNBURNED HYDROCARBONS (HC), CARBON MONOXIDE (CO), NITROGEN OXIDES (NOX) OR PARTICULATE MATTER (PM).

Particules (PM):‐ Les particules sont des résidus de carbones issus d’une combustion de fioul incomplète. Un ratio excessif de fioul/air, une mauvaise

dilution, un faible rendement de combustion ou des température de combustion trop faibles sont souvent la cause d’apparition de particules.

Emissions Control – Le compromis Nox/PM

NOx:‐ Les NOx se forment lorsque la température dans la chambre de combustion est trop élevée et proviennent de la combinaison de l’azote

dans l’air (78% azote/21 oxygène) avec l’oxygène. Le compromis PM/Nox est capital car certains paramètres qui permettraient d’abaisser les PM (comme une haute température de chambre) ont tendance à générer des Nox. les NOX se forment d'autant plus que la combustion dans le moteur est rapide et efficace, donc qu'elle a un bon rendement. En l'absence de système de traitement de NOX, une des solutions consiste à dégrader la combustion (augmentation de la consommation)

Fuel / Air Systems:‐ Le contrôle du process d’injection de fioul (multi injections) associé à un bon balayage de chambre permettent de maintenir un ratio

correct air/fioul et ainsi réduire les émissions de PM tout en maitrisant les émissions de Nox.‐ Retarder le timing d’injection et refroidir la charge d’air (aftercooler) aide à réduire les Nox.‐ Une haute pression d’injection permet d’améliorer la dilution, améliorer le rendement et ainsi réduire la formation de PM. Ces mêmes

paramètres peuvent également augmenter la température de combustion et ainsi générer davantage de Nox.

EGR (Exhaust Gas Recirculation): Reduces NOx‐ EGR réintroduit une partie des gaz inertes d’échappement dans la chambre de combustion, cela permet de réduire te taux d’oxygène

disponible et en réduire la température. Ces facteurs combinés réduisent la formation de Nox.‐ EGR peut réduire le rendement de combustion et la manqué d’air va générer la formation de PM.

1995 - Injection technologie :HEUI & Common rail, augmentation pressioninject, meilleur mélange et efficacité PM(-), Nox(+)

2014 - Aftertreatmenttechnologies• DOC• DPF• SCR

1985 - Air charge cooler, Nox (-)

1995 - Electronics and Control Software :Injection control timingNox (-) , Multiple injection Nox(-) PM(-)

2004 - NOx Reduction System (NRS),Nox(-), PM(+)

1955 -Turbochargers- Optimisation ratio air/fioul PM(-)

CATERPILLAR INNOVATIVE HISTORY

DENOX (Réduction des NOX par injection urée) / FILTRES SCR

POST TREATMENT SOLUTIONFILTRE A PARTICULES (Réduction des HC + C)

/ Filtres FAP

POT CATALYTIQUE (Réduction des HC + CO) / Filtres OXI

Ammonia Oxidation Catalyst (AMOX)

Présentation Eneria 201611

WHY IS SELECTIVE CATALYTIC REDUCTION (SCR) BEING USED WITH CAT ENGINES? (130 – 560 KW)

PROPOSITION DE CONFORMITÉ AUX EXIGENCES DE LA NORME NRMM 2016/1628 EURO STAGE V IWA & IWP ET EXAMEN DES MODALITÉS D'HOMOLOGATION


EU : NON ROAD ENGINES – IWW STAGE V

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C12 287 bkW / 390 HP @1800rpm - Test Spec : 0K5669/70 - Perfo Number : DM7528

PERFORMANCE DES MOTEURS ACTUELS

Emissions Control: EGR+DOC+DPF+SCR‐ DOC+DPF reduce PM. ‐ EGR+SCR reduce NOx.

Aftertreatment Thermal Management: Cat® Regeneration System

Advantages:‐ Conservative emissions solution, which minimizes total Fluid (Fuel+DEF) consumption in heavy duty, high use applications ‐meaning lower operating costs over time.

Disadvantages:‐ Higher initial price than competitive system.‐ Engine is higher weight.‐ Cooled EGR puts heat load into the cooling system, driving a larger cooling package than a non‐EGR engine.

Engine Specifications:Displacement: 12.5 / Cylinders: Inline‐6Power: 385‐520 hp (287‐388 bkW) Rated Speed: 1800‐2100 rpmEngine Weight: 2520 lb (1143 kg) Dims: 50.1x39.2x44.6in (1272x996x1132mm)

Fuel System: Mechanical Electronic Unit Injection (MEUI™)‐ The MEUI™ system provides the injection pressures and control needed to achieve engine performance and compliance with emissions standards.

Air System: Fixed Geometry Turbo‐ Turbocharger is a fixed geometry design that uses a balance valve inside the turbine housing to regulate turbine speed / boost pressure.

Cat® C13 ACERT™

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C18 447 bkW / 600 HP @1800rpm - Test Spec : 3717588 - Perfo Number : EM0075

PERFORMANCE DES MOTEURS ACTUELS

Engine Specifications:Displacement: 18.1L / Cylinders: Inline‐6Power: 575‐630 hp (429‐469 bkW) Rated Speed: 1800‐2000 rpmEngine Weight: 3399.5 lb (1542 kg)Dims: 56.6x38.1x49.1in (1438x969x1248mm)

Fuel System: Mechanical Electronic Unit Injection (MEUI™)‐ The MEUI™ system provides the injection pressures and control needed to achieve engine performance and compliance with emissions standards.

Air System: Fixed Geometry Turbo‐ Turbocharger is a fixed geometry design that uses a balance valve inside the turbine housing to regulate turbine speed / boost pressure.

Cat® C18 ACERT™

Emissions Control: EGR+DOC+DPF+SCR‐ DOC+DPF reduce PM. ‐ EGR+SCR reduce NOx.

Aftertreatment Thermal Management: Cat® Regeneration System

Advantages:‐ Conservative emissions solution, which minimizes total Fluid (Fuel+DEF) consumption in heavy duty, high use applications ‐meaning lower operating costs over time.‐ Simple, reliable turbo design.

Disadvantages:‐ Engine is higher weight.‐ Lower power density.

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EURO STAGE V CATERPILLAR SOLUTION


Emissions Control Methods – U.S. EPA Tier 4 Final / EU Stage IV

Aftertreatment Thermal Management: Maintains DPF and SCR Functionality‐ The SCR system must maintain 200‐250°C temperature to function properly. ‐ When a DPF is present, the active regeneration system can both regenerate the DPF and provide heat to keep the SCR system at temperature. Burner systems, like the Cat®Regeneration System, are the most fuel efficient and effective strategy for aftertreatmentthermal management. This system is transparent and automatic, requiring no operator interaction, and can perform during the work cycle with no interruption. ‐ When no DPF is present, other technologies are used to manage SCR temperature. These components include backpressure valve, intake throttle valve, VGT, and other strategies to artificially increase load on the engine. Loading the engine in this manner is inefficient and increases fuel consumption.

DOC (Diesel Oxidation Catalyst): Reduces PM and helps SCR system‐ A diesel oxidation catalyst (DOC) has the ability to promote desirable oxidation of several exhaust gas components (ie add oxygen), oxidizing carbon monoxide, gaseous hydrocarbons, soluble organic fraction of PM into carbon dioxide and water. It also can promote the undesirable reaction of sulfur dioxide to sulfuric acid, minimized by the use of low sulfur diesel fuel.

DPF (Diesel Particulate Filter): Reduces PM‐ DPF traps Particulate Matter (soot & ash), which is then burned away periodically by a “regeneration”. “Active Regeneration” relies on a burner that provides heat to the DPF by burning fuel. “Passive Regeneration” relies on exhaust heat to burn away the soot.

SCR (Selective Catalyst Reduction): Reduces NOx‐ SCR uses Diesel Exhaust Fluid (DEF) in the presence of a precious metal catalyst to convert NOx into Nitrogen and Water. SCR is highly effective at removing NOx.‐ Amount of DEF required by the SCR system is directly related to the amount of engine‐out NOx that needs to be reduced.

DEF (Diesel Exhaust Fluid):‐ DEF is a urea‐based fluid that is used to convert NOx into Nitrogen and Water by the SCR system.‐ DEF is stored in a tank and a pump is used to distribute the fluid to the SCR system.

Cat Clean Emissions Module (CEM) 130-560 kW (175-750 hp)

•DEF InjectorInjects DEF into Mixing pipe

•Mixing pipePart of exhaust stream post-DPFMixes DEF and hot exhaust gas to form ammonia

•SCR catalystCatalyzed flow-through substrateNOx reacts with ammonia over catalyst reducing NOx. Converts to nitrogen and water

•Ammonia Oxidation Catalyst (AMOX)Catalyzed flow-through substrateTrace amounts of ammonia not converted is further broken down to nitrogen

SCR reduces NOx emissions up to 93%

DENOX SYSTEM SCR

PARTICULE FILTER & DENOX SYSTEM

Project key points• First IMOIII project carried out by BRITTANY FERRIES

on NORMANDIE EXPRESS• C18 engines family and group concept definition with

BV• NOx reduction definition with HUG engineering• E2 D2 E3 cycles run on UTAC test cells• First complete “Turn Key” Project with ENERIA Marine

lead on refit ( Mechanical & Electrical integration on site)

IMO III compliance :• Partnership with HUGENGINEERING for development of

dedicated solution and edition of technical file (Systems : SCR system from HUG MCE4.40)

Eneria Caterpillar Marine executive meeting - June 1625

CERTIFICATION IMO III

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EXAMPLE of DPF + SCR system integrationC32 CATERPILLAR Genset – Caissonier BOUYGUES

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CAT CEM – Higher power range / Marine SCR unit

C32 EPA T4 / IMO III CEM OVERALL DESIGN

Inlet Sensor Box• NOx In• Abs Pressure• Inlet Temp

Urea InjectorExtended Lance 60 L/hr Capacity

Mixers2 Flapper mixers to promote evaporation and urea distribution

Inlet and Outlet Spool12” ANSI FlangeRotatable to accommodate Multiple installation configurations

Structural Skeleton¼ Plates combined with Catalyst Sleeves creates ridged honeycomb core

Service Access DoorDown Steam of Catalyst

4x Mounting Feet Configurable for several isolated Mounting configurations

Outlet Sensor Box• NOx Out• Temp Out

Serviceable CatalystOptimized for marineservice requirements

4x Lifting Link

Flute + NOx MixerPromotes Outlet NOxAccuracy and precise closed Loop control

Exhaust InExhaust Out

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C32 EPA T4 / IMO III CEM DIMENSIONS & INTEGRATIONU Flow

Z Flow

597mm

597mm

Weight: ~500 kg for C32 engine – 6bricks

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3500 CEM DIMENSIONS & INTEGRATION

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IMO III FLUIDS REQUIREMENTS

ULSD REQUIRED FOR TIER 4 INTERIM & IMOIII PRODUCT U.S. EPA Tier 4 regulations require the use of commercial ULSD that conformswith the ASTM D975 specification of 15 ppm max sulfur fuel.IMO III requires that the fuel sulfur levels are below 1,000ppm.

ECF-3 API CJ-4 OIL REQUIRED: Reduced sulfated ash, phosphorous, and sulfurTo maintain DPF performance and cleaning cycles

DEF 32,5% UREA 67,5% DEIONIZED WATER OR COMMERCIAL AD-BLUE SATISFYING ISO 22241-1

DEF STORAGE IN COLD AND DRY ENVIRONNEMENT -9°C TO 25°C

Oil inlet cap/fill neck label

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IMO III CEM MAINTENANCE

500 HOURSEngine oil and filter change, fuel filters changeInspect, adjust, and or replace belts

2000 HOURS OR 1 YEARFumes Disposal Filter

250 HOURSInitial engine valve lash check

5000 HOURSDPF clean ARD spark plug – replaceUrea Injector – replaceUrea Filter - Replace

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WELDINGWelding on Cat CEM frame/chassis & Dosing Cabinet is prohibited.

INTEGRATIONCEM casing thermal expansion (7‐15mm). Bellows & flexible mounts required

PAINTINGPainting of Caterpillar CEM is NOT recommended and strongly discouraged.

DEF FILTRATIONThe DEF supply to the dosing cabinet inlet should be filtered (40 microns ).

MATERIAL COMPATIBILITY WITH DEFBase material and their alloys of copper, zinc, aluminum and magnesium material containing silver and nickel coatings are not compatible with DEF. Carbon steels, zinc coated carbon steels, and mild iron are not to be used with DEF. Do not store DEF in a tank or use supply lines or fittings that are made of the above materials.

ALL CONNECTION POINTS AND FITTINGS FOR THE DEF LINES ARE REQUIRED TO BE STAINLESS STEEL OR DEF COMPATIBLE MATERIAL. ISO 22241-3 HAS A LIST OF DEF COMPATIBLE MATERIALS.

IMO III SHIPYARD & END USER INSTALLATION REQUIREMENTS

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TOUTES NOS ÉNERGIES POUR VOS PROJETS


règlement engins mobiles non routiers eu : non road … · 2018. 10. 10. · 1995 -injection...

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